Rectangular Wound Core Corner Structure for Low Iron Loss
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Solution Overview
Problem
Existing methods of producing wound cores by bending steel sheets with a small radius of curvature result in inefficiencies due to variations in intermediate layer thickness and form, leading to inadvertent deterioration in magnetic properties.
Innovation Solution
A wound core design with specific constraints on the thickness and distribution of the intermediate layer, ensuring that the sum of bent angles in corner portions is 90°, and the inner side radius of curvature ranges from 1 mm to 5 mm, with controlled thickness variations to minimize strain and maintain magnetic efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If steel sheets are bent with a small radius of curvature to form corner portions, then the manufacturing process becomes simpler and annealing can be omitted, but the intermediate layer thickness varies and magnetic properties deteriorate
Solution Approach 1:
The patent applies local quality by differentiating the intermediate layer structure in different regions: in the bent corner portions, the intermediate layer is formed with controlled thickness variations, while in the flat portions, the intermediate layer maintains uniform thickness. This localized differentiation allows the bent portions to accommodate strain without compromising overall magnetic properties, while maintaining manufacturing simplicity.
Solution Approach 2:
The patent changes the thickness parameter of the intermediate layer specifically in the bent portions, allowing thickness variations within controlled ranges (e.g., 5-20 nm in bent portions versus more uniform thickness in flat portions). This parameter modification enables the structure to accommodate bending strain while maintaining adhesion and minimizing magnetic property deterioration.
2Strength
If the intermediate layer is made thicker to ensure adhesion, then adhesion is improved, but iron loss increases due to domain wall motion interference
Solution Approach 1:
The patent optimizes the intermediate layer thickness parameter to a specific range (5-20 nm) that balances adhesion and iron loss. This thin but sufficient thickness provides the necessary anchoring effect for adhesion while minimizing the interference with domain wall motion, thereby reducing iron loss compared to thicker intermediate layers.
Solution Approach 2:
The patent applies different intermediate layer thicknesses in different regions: thinner layers (5-20 nm) in bent portions where strain occurs, and more uniform thickness in flat portions. This localized quality control ensures adequate adhesion where needed while minimizing domain wall interference in regions where magnetic properties are critical.
3Strength
If the intermediate layer interface is made uneven to enhance adhesion, then adhesion is improved, but iron loss increases due to domain wall motion hindrance
Solution Approach 1:
The patent creates localized interface unevenness only in the bent corner portions where adhesion is most critical, while maintaining smoother interfaces in the flat portions. This localized approach provides the anchoring effect where strain occurs without creating excessive domain wall interference in the magnetic flux paths.
Solution Approach 2:
The patent controls the roughness parameter of the intermediate layer interface, allowing greater unevenness in bent portions (to enhance adhesion) while maintaining smoother interfaces in flat portions (to reduce iron loss). This differential parameter control resolves the contradiction between adhesion and energy loss.
Data Source
AI summary
This wound core is a wound core including: a substantially rectangular wound core main body in a side view in which first planar portions and corner portions are alternately continuous and at least one of two or more bent portions existing in at least one corner portion satisfies Equations (1) to (3) below.Tave≤40 nm (1)(To−Tu)/Tave≤0.50 (2)Tave(To−Tu)≤240 nm2 (3)